Modular-unit floodwall system

ABSTRACT

A modular-unit floodwall system is disclosed. The system includes modular floodwall units configured for holding water and connecting and sealing devices for connecting the units together to form a barrier against floodwater. A method of constructing such a floodwall is also disclosed.

FIELD OF THE INVENTION

The present invention generally relates to floodwall systems, and more particularly to a floodwall system constructed of modular units which can be readily configured to meet site-specific requirements.

BACKGROUND OF THE INVENTION

Every year flooding caused by melting snow and heavy rains results in extensive property damage, economic losses, disruption of business and personal activities, and injury and suffering to both humans and animals. Various types of barricades are used to control flooding, e.g., permanent floodwalls and dams, earthen dikes and levees, and temporary structures such as sandbag barriers. All such barricades have various drawbacks, including high installation costs, labor-intensive deployment, ineffective flood control, and/or substantial clean-up after flooding has subsided. There is a need, therefore, for an effective, cost-efficient flood mitigation system which can be readily customized to meet the needs of virtually any site to be protected against flooding, and which is also able to be readily deployed and readily removed with minimal clean-up.

SUMMARY OF THE INVENTION

This invention is directed to a modular-unit floodwall system comprising modular floodwall units adapted for holding water. Each unit has a bottom wall, opposite end walls and side walls. The system also includes connecting and sealing devices for connecting the modular units and sealing junctions between the modular units to form a barrier against floodwater. In one embodiment, each connecting and sealing device comprises a footer configured for connecting two units together generally adjacent the bottom walls of the units, a header configured for connecting the two units together adjacent the top walls of the units, and a generally vertical connecting member connecting the footer and the header and extending across a junction between the two units. A seal on the connecting member is provided for sealing the junction.

One type of modular floodwall unit comprises a rigid box-like structure having a top wall, a bottom wall, opposite end walls and opposite side walls. The structure has a water-holding capacity of at least 1800 cubic feet and at least one opening in the top wall. A pump-guide system is provided on the top wall for guiding a mobile pump along the top wall.

Another type of modular floodwall unit for controlling flood water comprises an elongate rigid structure having a bottom wall, opposite end walls, and a pair of corner posts extending up from the bottom wall adjacent the end walls. A first generally vertical side wall extends up from the bottom wall and is secured to the corner posts, and a second inclined side wall slopes up from the bottom wall to the vertical side wall. Openings are provided in upper and lower ends of the corner posts for receiving connecting devices for connecting the modular floodwall unit end-to-end to adjacent modular floodwall units. The structure has a generally triangular shape as viewed from an end of the structure.

This invention is also directed to a method of constructing a floodwall from modular floodwall units comprising a first plurality of first modular units having a first water-holding capacity and a second plurality of second modular units having a second water-holding capacity less than said first water-holding capacity. The method comprises the steps of connecting a plurality of first modular units and a plurality of second modular units together, and sealing junctions between the modular units to form a floodwall.

Other objects and features will be in part apparent and in part pointed out hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view of a floodwall system constructed of modular floodwall units of this invention;

FIG. 2 is a plan schematic view of six modular floodwall units connected end-to-end and side-to-side;

FIG. 3 is a perspective view of a first modular floodwall unit having a pump-guide system on a top wall of the unit;

FIG. 4 is a perspective view similar to FIG. 3 but showing a door of the unit open to access a dry-storage compartment;

FIG. 5 is an exploded view showing parts of a bulkhead inside the unit;

FIG. 6 is an enlarged view showing details regarding a frame of the bulkhead;

FIG. 7 is a front elevation of the assembled bulkhead but with one bulkhead panel removed to show a portion of the frame;

FIG. 8 is a sectional view showing a drain port in the bulkhead;

FIG. 9 is a side elevation of the first modular floodwall unit of FIG. 3 and a pumping unit movable along the pump-guide system;

FIG. 10 is an enlarged vertical section taken in the plane of lines 10-10 of FIG. 3;

FIG. 11 is a perspective view similar to FIG. 3 but showing the pump-guide system at a different location on the top wall;

FIGS. 12 and 13 are schematic views illustrating how a pumping unit on the pump-guide system can be used to fill a modular floodwall unit; and

FIGS. 14 and 15 are schematic views illustrating alterative ways to fill a modular floodwall unit;

FIG. 15A is a perspective or a first modular floodwall unit with a swivel fitting for connection to a down-mover hose for filling and/or emptying the unit;

FIG. 16 is a front perspective view of a second modular floodwall unit of the system;

FIG. 17 is a rear perspective view of the second modular floodwall unit of FIG. 16;

FIG. 18 is a perspective of two second modular floodwall units nested together for transport and/or storage;

FIG. 19 is a perspective illustrating how a connecting and sealing device of this invention is used to connect two modular floodwall units to one another and to seal a junction between the two units;

FIG. 20 is a perspective of a footer of the connecting and sealing device of FIG. 19;

FIG. 21 is a partial bottom plan view showing openings in two adjacent modular units for receiving mating connectors on the footer of the connecting and sealing device, and further showing a vertical connecting member and gasket of the connecting and sealing device for sealing the junction between the two units;

FIG. 22 is a perspective of a header of the connecting and sealing device of FIG. 19;

FIG. 23 is a front elevation of a connecting member for connecting header and footer components of the connecting and sealing device;

FIG. 24 is an enlarged horizontal section taken in the plane of lines 24-24 of FIG. 19;

FIG. 25 is a rear elevation of the connecting member, showing a gasket on the back face of the member;

FIG. 26 is rear perspective of the connecting member and gasket;

FIG. 26A is a view showing an optional locking feature for the connecting member;

FIG. 27 is a front perspective of an expansion connecting and sealing device as used to connect two modular floodwall units to one another and to seal the junction between the units;

FIG. 28 is a perspective of a footer member of the expansion connecting and sealing device;

FIG. 29 is a perspective of a header member of the expansion connecting and sealing device; and

FIG. 30 is an enlarged horizontal section taken in the plane of lines 30-30 of FIG. 27.

Corresponding reference characters indicate corresponding parts throughout the drawings.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings, and more particularly to FIG. 1, an exemplary modular-unit floodwall system of the present invention is designated in its entirety by the reference numeral 20. As illustrated, the floodwall is positioned to control the flooding of a waterway such as a river to minimize damage to real estate, facilities and/or communities along the waterway (“protected property”) in FIG. 1).

In general, the system 20 comprises a series of modular floodwall units adapted for holding water. In one embodiment, the units comprise a first plurality of first modular units, each generally designated 24, having a first configuration (e.g., a first water-holding capacity) and a second plurality of second modular units, each generally designated 28, having a second configuration (e.g., a second water-holding capacity different from the first water-holding capacity of the first units). The system also includes connecting and sealing devices, each generally designated 34, for connecting the units 24, 28 together either end-to-end or end-to-side and for sealing junctions 30 (i.e., gaps or seams) between the units to form a barrier against floodwater. FIG. 2 shows one configuration in which six modular floodwall units 24 are connected end-to-end and end-to-side. (FIG. 2 is a schematic view which omits certain details of the units.) As discussed below, other configurations are possible.

FIGS. 3 and 4 illustrate one of the first modular units 24. The unit comprises a rigid elongate box-like structure 40 having a top wall 42, a bottom wall 44, opposite end walls 48 and opposite side walls 52. As viewed from one (either) end, the structure is generally rectangular in shape. The dimensions of the structure 40 may vary, but it typically will have a water-holding capacity of at least 1800 cubic feet. By way of example but not limitation, the structure 40 may have a width W1 of about eight feet, a height Hi of about 8.5 feet, and a length L1 which can vary from about 20 feet to about 80 feet (e.g., 20 feet, 40 feet, 48 feet, and 53 feet). When filled with water, the structure 40 is very heavy (e.g., about 70 tons for a modular unit 40 feet long).

Desirably, the structure 40 has a rugged construction similar that of an intermodal shipping container, making it durable and re-usable, even when subjected to harsh weather conditions, flood waters, floating debris, etc. The top wall 42, bottom wall 44, side walls 52 and one end wall 48 of the structure 40 are constructed of heavy-duty corrugated sheet metal supported by four corner posts 60 connected at their upper and lower ends by upper and lower longitudinal beams 64 extending the length of the structure and transverse beams 68 extending the width of the structure. The other end wall 48 comprises a door 70 of plate metal (e.g., 3/16 in.-thick plate metal) comprising two door leafs pivoted on respective corner posts 60. The door is equipped with suitable seals (not shown) to make the door water-tight. Other door configurations are within the scope of this invention.

The structure 40 can be made of strong, durable materials other than metal, such as carbon-fiber materials that may have honey-comb interiors. The use of material lighter than steel, for example, has the advantage of reducing costs associated with transportation and assembly of a floodwall. The cost of manufacture may also be reduced. However, one disadvantage of using lighter materials is that steel adds weight which increases the stability of the structure 40 against forces exerted by flooding waters tending to tip or slide the structure. If necessary or desirable, the stability of structures made of lighter material can be increased by adding mechanical means such as pilasters or outriggers to the structure.

Referring to FIGS. 4-7, each structure 40 defines an interior space divided by a bulkhead 76 into a water-holding tank compartment 78 and a dry storage compartment 80 accessed by the door 70. The bulkhead 76 comprises a rectangular frame 82 made, for example, from angle-bar frame members 82A secured to respective top, bottom and side walls of the structure, a vertical frame member 86 at the center of the rectangular door frame 82, and a pair of metal panels 88 affixed (e.g., welded) to the frame members 82A, 86. (Only one bulkhead panel 88 is shown in FIGS. 5 and 7 so that details of the frame 82 are more apparent.) Desirably, the construction is such that the frame members 82A, 86 and panels 88 can be installed from the storage-compartment side of the bulkhead 80. The dry storage compartment 80 is relatively small (e.g., extending in about two feet from the end wall 48) compared to the water-holding tank compartment 78 and is used for storing accessories, such as pump components, hoses, etc. The water-holding tank compartment 78 has a water-holding capacity which will vary according to its size. As noted above, the compartment is typically sized to have a water-holding capacity of 1800 cubic feet or more.

Alternatively, the bottom wall 44 of the structure 40 may be made of wood. In such case, one or more receptacles (e.g., flexible bladders and/or rigid tanks of PVC or other suitable material) supported in cradles may be placed inside the water-holding tank compartment 78 for holding water. This type of unit will typically have a lower water-holding capacity (and thus a lighter weight) and may be more appropriate for use at locations where the flood waters are relatively shallow and/or slow-moving. A series of such units, each designated 24′, are shown in FIG. 1.

On a related note, conventional intermodal containers can be modified to use as structures 40. Such containers typically have a wood floor which can be replaced with a metal bottom wall 44. Alternatively, one or more receptacles can be placed in the container to hold water, as discussed above.

As shown in FIGS. 3, 4 and 9, a pump-guide system, generally designated 100, is provided on the top wall 42 of each structure 40 for guiding one or more mobile pumps 108 along the top wall (FIG. 9). In the illustrated embodiment, the pump-guide system 100 comprises a pair of rails 102 located on opposite sides of the longitudinal centerline of the top wall. The rails 102 are generally L-shaped in cross section (e.g., angle bars) and form a guide track for rolling engagement by the wheels of a mobile pump unit 108. One or more openings 110 are provided in the top wall 42 of the structure 40 for pumping water into and out of a respective floodwall unit 24. If the mobile pump unit 108 is particularly heavy (some units weigh 3100 pounds or more), the top wall 42 may be reinforced by exterior or interior transverse roof reinforcing beams 114 (e.g., tubular steel beams) extending within the valleys of the corrugations of the top wall from one side of the structure 40 to the other (FIG. 10). Desirably, the beams 114 are welded or otherwise secured to the rails 102 so that the entire rail-and-beam assembly can be transported to the flood site as a prefabricated assembly and then simply laid in place on the top wall 42 of a structure 40 with the reinforcing beams 114 in the valleys of the corrugations and the rails resting on the flat peaks of the corrugations. Alternatively, as illustrated in FIG. 11, the rails 102 may be placed off-center closer to a side wall 52 of the structure 40 for support by the longitudinal upper beam 64 of the unit at that side of the unit.

The rails 102 allow the mobile pump unit 108 to move as needed along the top wall 42 of the structure 40, and between adjacent units 24 connected end to end, to fill the water-holding tank compartments 78 of the modular units 24. By way of example, as shown in FIGS. 12 and 13, the inlet of the pump unit 108 may be attached to an inlet hose 110 for receiving water from a suitable source, and the outlet of the pump may connected to an outlet hose 112 for delivering water to the water-holding tank compartment 78 through one or more openings 116 in the top wall 42 of the modular unit. If necessary or desirable, the pump unit 108 can be used on the ground to pump water from either side of the unit 24, as illustrated, for example, in FIG. 14. The water can be pumped from any available water source, such as a waterway near the modular unit 24 or far from the unit (e.g., up to 2000 feet away, depending on the size of the pump unit 108. Alternatively, the water can be pumped from a community water system, such as the fire hydrant 120 shown in FIG. 15). The pump unit 108 is sized to have the appropriate water-pumping capability, e.g., 350-2800 gallons/minute.

If needed or desired, the modular units 24 can be also be filled without using one or more pumping units 108, e.g., by using available pressurized water sources such as hydrants or fire pumpers.

FIG. 15A illustrates a swivel connection, generally designated 122, secured to the top wall 42 of a modular unit 24. The connection 122 comprises a generally L-shaped pipe fitting 124 rotatable about a generally vertical axis. The fitting has a first (upper) end 124A configured for quick-connection to and quick-disconnection from a pump or hose (not shown) supplying water to fill the water-holding tank compartment 78, and a second (lower) end 124B configured for quick-connection to and quick-disconnection from a hose or other conduit 126 extending down into the compartment 78 to a location generally adjacent the bottom wall 44 of the unit. The pipe fitting 124 can be rotated to any convenient angle to facilitate connection to a pump unit 108 or other source of water on the ground, thus eliminating the need for the pump-guide system 100 and openings 116 in the top wall 42 of the modular floodwall unit 24.

The modular floodwall unit 24 has self-fill openings 130 spaced at intervals along the side walls 52 of the unit (see FIGS. 3 and 4). In the event flood waters rise to the level of these openings 130, water will flow into the water-holding tank compartment 82 of the unit to fill it. Desirably, the self-fill openings 130 are spaced a substantial distance, e.g., seven feet, above the bottom wall 44 of the unit and are sufficiently small to prevent large debris from entering the unit.

The modular unit 24 has a drainage system for draining water from the water-holding tank compartment 82. As illustrated in FIGS. 7 and 8, the system comprises one or more drain ports 134 adjacent the lower ends of the bulkhead panels 88. Additional drain ports (not shown) can also be provided in the end wall 48 at the opposite end of the unit. Each drain port 134 comprises a pipe 138 and a removable cap 140 threaded on the pipe. After flooding has subsided, water is removed from the water-holding tank compartment 78 using the mobile pump unit 108. The water-holding tank compartment 82 is cleaned by removing the cap 140 from each drain pipe 138 and flushing the compartment with fresh water which drains out through the (now open) pipe.

The second modular units 28 are configured to have a smaller water-holding capacity, e.g., one-half the capacity of the first modular units 24 (see FIGS. 17 and 18). Each second modular unit 28 comprises an elongate rigid structure 160 having a bottom wall 162, opposite end walls 166, and two corner posts 168 extending up from the bottom wall adjacent opposite end walls. The structure 160 also has a first (front) generally vertical side wall 170 secured to the corner posts 168 and a second (back) inclined side wall 172 sloping up from the bottom wall to the first side wall 170 at a suitable angle A (e.g., in the range of 35-65 degrees, such as about 45 degrees as shown in FIG. 16). Thus, as viewed from either end, the structure 160 has the general shape of a triangle and, in particular, a right-triangle. The structure 160 may have other triangular shapes (e.g., both side walls 170, 172 may be inclined). The dimensions of the structure 160 may vary, but it typically will have a water-holding capacity of at least 1200 cubic feet. By way of example but not limitation, the structure 160 may have a width W2 of about eight feet, a height H2 of about 8.5 feet, a length L2 which can vary from about 20 feet to about 80 feet (e.g., 20 feet, 40 feet), and a distance D1 along the inclined side wall from the bottom to the top of the unit of about 11.5 feet. When filled with water, the modular unit 28 is very heavy (e.g., at least about 40 tons), but not as heavy as the first modular unit 24. As a result, the second modular unit 28 is ideal for placement on levees, and/or around plants, warehouses and other property assets that are located in slow-moving flood waters (see FIG. 1), and/or on streets and other structures which might be damaged if subjected to the full weight of the water-filled first modular unit 24 described above.

The second modular unit 28 is also of rugged and durable construction. The bottom wall 162, end walls 166 and side walls 170, 172 are constructed of heavy-duty corrugated sheet metal supported by the two corner posts 168. The corner posts 168 are connected at their upper and lower ends by upper and lower longitudinal beams 184 extending the length of the structure. The corner posts 168 are also connected at their lower ends by transverse beams (not shown) extending the width of the structure. In the illustrated embodiment, the second modular unit 28 does not have an interior bulkhead. Desirably, the unit 28 has self-filling openings 186 in both side walls 170, 172 spaced a suitable distance D2 (e.g., seven feet) above the bottom wall 162. Drainage ports 188 are provided in the end walls 166 to facilitate emptying and cleaning of the unit.

The triangular design of the second modular unit 28 has certain advantages. Because it is smaller than the first modular unit 24, it is less expensive to fabricate and requires less time to set up and fill in the field. Further, the triangular shape of the unit 28 permits two units to be stacked one on top of the other in a nested arrangement, as shown in FIG. 18, for compact transport to and from the flood site. Straps 190 can be used to secure the two units 28 to one another during transport. The two corners of each unit 28 at the juncture of the bottom wall 162 and inclined side wall 172 are notched as indicated at 194 to receive the corner posts 168 of a unit 28 stacked on it.

The second modular unit 28 can be installed with its vertical side wall 170 facing the flood waters or with its inclined side wall 172 facing the flood waters. The latter is generally desirable in situations where the flood waters are exerting large lateral forces on the unit, because the weight of the water overlying the inclined side wall 172 will increase the frictional resistance of the unit against lateral movement due to such forces, thus making the unit more stable.

FIG. 19 illustrates components of a modular connecting and sealing device 34 for connecting the modular units 24, 28 and sealing the junctions 30 between them to form a floodwall (e.g., floodwall 20). Desirably, the same device 34 may be used for connecting two first modular units 24 to one another, and two second modular units 28 to one another, and first and second modular units 24, 28 to one another. Further, the device 34 may be used to connect the modular units end-to-end or end-to-side, as shown for example in FIG. 2. For convenience, the connecting and sealing device 34 is described immediately below in the context of connecting two first modular units 24 to one another.

In general, the device 34 comprises a footer 200 configured for connecting two modular units 24 together generally adjacent the bottom walls 44 of the units, and a header 204 configured for connecting the two units together at a location spaced above the bottom walls of the units (e.g., adjacent the top walls 42 of the units as illustrated). The device 34 also includes a generally vertical connecting member 210 that connects the footer 200 and header 204 and extends across the junction 30 between the two units. A seal 214 (FIG. 24) on the connecting member 210 is provided for sealing the junction 30. Each of these components is described in detail below.

Referring to FIG. 20, the footer 200 comprises a generally rectangular base 220 having connector components comprising a pair of spaced-apart posts 224 extending up from the base. The posts 224 are configured for releasable connection with mating connector components 228 on the two modular units 24 being connected. In the embodiment illustrated in FIGS. 19-21, these mating connector components 228 comprise holes (also designated 228) in the lower ends of respective corner posts 60 of the two modular units 24 (FIG. 21). The posts 224 on the footer 200 are sized for a relatively snug fit in the holes 228 of the corner posts 60. The base 220 and posts 224 of the footer 200 are suitably dimensioned. By way of example but not limitation, the base 220 may be a metal plate having a length L3 of about 13 in., a width W3 of about 9.0 in. and a thickness T3 of about 1.0 in., and the posts 224 may be formed by tubular metal pipes welded to the base each having a height H3 of about 3.5 in. and an outside diameter OD of about 1.875 in. The mating connector components on the footer 200 and modular units 24 may have other configurations within the scope of this invention.

As shown in FIG. 22, the header 204 comprises a generally rectangular base 240 having connector components comprising a pair of spaced-apart posts 244 extending down from the base. The posts 244 are configured for releasable connection with mating connector components 250 on the modular units 24 being connected. In the illustrated embodiment (FIGS. 19 and 22), these connector components 250 comprise holes (also designated 250) in the upper ends of respective corner posts 60 of the two modular units 24. The posts 244 on the header are sized for a relatively snug fit in the holes 250 of the corner posts 60. The base 240 and posts 244 of the header 204 are suitably dimensioned, and desirably have a construction identical to the base 220 and posts 224 of the footer 200. By way of example but not limitation, the base 240 may be a metal plate having a length L4 of about 13 in., a width W4 of about 9.0 in. and a thickness T4 of about 1.0 in., and the posts 244 may be formed by tubular metal pipes welded to the base each having a height H4 of about 3.5 in. and an outside diameter OD of about 1.875 in. The mating connector components on the header 204 and modular units 24 being connected may have other configurations within the scope of this invention.

Referring to FIGS. 23-25, the connecting member 210 comprises an elongate generally rectangular plate or panel 260 having opposite ends 262, 264. The ends are configured (e.g., tongue-shaped) for removable reception in openings comprising slots 270, 272 in the bases 220, 240 of the footer 200 and header 204, respectively. Desirably, the connecting member 210 is reversible so that either end 262, 264 may be inserted through the slot 270 in the footer 200. One end 262 has an end face 276 which is smooth for use on hard surfaces like asphalt, heavy aggregate and concrete, and the other end 264 has an end face formed with teeth 280 for use on soft ground, dirt, small gravel, grass and clay surfaces. The connecting member 210 has side margins 284 along its opposite sides which are bent inward for reception in the corrugations of the side walls 52 of the two units 24 being connected, as shown in FIGS. 19 and 21. The side margins 284 have upper and lower edges spaced a distance D5 from respective upper and lower ends 262, 264 of the connecting member 210 to accommodate the longitudinal beams 62 extending along the sides of the units 24. The connecting member 210 is dimensioned such that when it is in place, it extends substantially the full height of the modular units 24 and spans the junction 30 between the units. By way of example, the connecting member 210 may have an overall length L5 of about 10.125 feet, an overall width W5 of about 22.0 in., and a dimension D3 of about 7.5 in. The connecting member 210 may be constructed from a metal plate having a thickness of 0.125 in.

The seal 214 comprises a gasket (also designated 214 in FIGS. 24-26) of compressible sealing material (e.g., a sealing foam material) on an inner surface of the connecting member panel 260 (facing the units 24 being connected). By way of example, the gasket 214 may be a 1.0 in. to 1.5 in.-thick sheet of closed-cell, water-resistant foam material having a peel-off backing layer for ready application of the foam to the connecting member 210. When the connecting member 210 is in place, the gasket 214 is compressed between the inner surface of the connecting member panel 260 and the side walls 52 of the two units 24 being connected, as illustrated in FIG. 24. The gasket 214 spans the junction 30 between the two units 24 and seals it.

When the connecting member 210 is in place, the upper and lower ends 262, 264 of the connecting member project through respective slots 270, 272 of the footer 200 and header 204. Optionally, as shown in FIG. 26A, holes 290 may be provided in the ends of the connecting member so that the end of the connecting member extending up through and beyond the header slot 272 is able to receive a removable locking pin or key 294 to prevent unintentional withdrawal of the connecting member from the slot 272 in the header 204. The locking pin 294 is threaded to receive a nut 296 to hold the pin in place. Other locking devices may be used, if desired.

One or two connecting and sealing devices 34 are used to connect two modular units 24, depending on the desired configuration of the floodwall. If two units 24 are connected in an end-to-end configuration as shown in FIG. 19, two connecting and sealing devices 34 are used to connect the two units. In this configuration, a first device 34 is used on the flood water side of the two units and a second device 34 is used on the opposite (flood-protected) side of the two units. If two units are connected in an end-to-side configuration, as shown in FIG. 2, only one device 34 is used at the waterway side of the two units.

For added sealing protection, an additional seal 300 may be placed between the end walls 48 of the two modular units 24 being connected (FIGS. 19, 21 and 24). The seal 300 comprises a gasket of compressible sealing material (e.g., a sealing foam material). The gasket 300 is adhesively secured in place to the end wall 48 of one unit 24 before the two units are connected. The thickness of the gasket 300 is such that it is compressed between the end walls 48 when the modular units are connected. By way of example, the gasket 300 may be a 1.0 in. to 3.5 in.-thick sheet of closed-cell, water-resistant foam material having a peel-off backing layer for ready application of the foam to an end wall of one of the modular units.

The sealing and connecting device 34 described above can also be used to connect two smaller (second) modular units 28 illustrated in FIGS. 16 and 17. If used in this manner, the posts 224 on the footer 200 of the device 34 are received in holes (not shown) in the lower ends of adjacent corner posts 168 of the two units 28 being connected. Similarly, the posts 224 on the header 204 of the device 34 are received in holes 314 in the upper ends of adjacent corner posts 168 of the two units 28 being connected. The connecting member 210 connects the footer 200 and header 204, and the seal 214 on the connecting member seals the junction 30 between the two units 28.

The sealing and connecting device 34 described above can also be used to connect a first modular unit 24 and a second modular unit 28. If used in this manner, one of the posts 224 on the footer 200 of the device 34 is received in the hole 228 in the lower end of a corner post 60 of the unit 24 and the other post 224 on the footer is received in the hole (not shown) in the lower end of the adjacent corner post 168 of the unit 28. Similarly, one of the posts 224 on the header 204 of the device 34 is received in the hole 250 in the upper end of a corner post in the unit 24 and the other post 224 is received in the hole 314 in the upper end of the adjacent corner post 168 of the unit 28. The connecting member 210 connects the footer 200 and header 204, and the seal 214 on the connecting member seals the junction 30 between the two units 24, 28.

FIGS. 27-30 illustrate an “expansion” connecting and sealing device of this invention, generally designated 320. This device 310 is similar to the device 34 described above except that it has a footer comprising two separate, spaced apart footer members, each designated 324, having connector components 326 configured for releasable connection with the mating connector components 228 on two modular units 24 being connected. The device 320 also has a header comprising a pair of separate, spaced apart header members, each designated 334, having connector components 338 configured for releasable connection with the mating connector components 250 on the two modular units 24. The connecting and sealing device 310 also includes a relatively wide connecting member comprising a generally rectangular expansion plate or panel 350 having top, bottom and side edges configured for removable reception in respective openings 354 in the footer and header members 324, 334. The width of the expansion panel 350 can vary has needed or desired. By way of example, the panel 350 may have a width of three feet, five feet, eight feet, ten feet, or other suitable dimension. The panel 350 has a height generally corresponding to the full height of the modular units 24 being connected.

Referring to FIG. 28, each footer member 324 comprises a base 360, and the connector component 326 comprises a tubular post (also designated 326) extending up from the base for removable reception in the hole 228 at the lower end of a corner post 60 of a respective modular unit 24, much like the connector post 224 of the footer 200 previously described. Similarly, as shown in FIG. 29, each header member 334 comprises a base 366, and the connector component 338 comprises a tubular post (also designated 338) extending down from the base for removable reception in the hole 250 at the upper end of the corner post 60, like the connector post 244 of the header 204 previously described. The openings 354 for receiving the edges of the expansion panel 350 are defined by generally U-shaped channels 370, 372 on the footer and header members 324, 334, respectively. The channels 370 on the footer members 324 open upwardly and laterally outwardly toward one another. The channels 372 on the header members 334 open downwardly and laterally outwardly toward one another.

By way of example but not limitation, the base 360 of the footer member 324 may be in the form of a metal plate having a length L6 of about 13 in., a width W6 of about 6.5 in. and a thickness T6 of about 0.5 in., and the posts 316 of the footer members may be formed by tubular metal pipes welded to the plate, each such pipe having a height H6 of about 3.5 in. and an outside diameter OD of about 1.625 in. (see FIGS. 28 and 29). The channels 370, 372 may also be formed from metal plate having an overall height H7 of about 5.5 in., an opening width W7 of about 5.5 in., an opening depth D7 of about 6 in., and a thickness T7 of about 0.5 in. The footer members 324 can have other configurations without departing from the scope of this invention.

Similarly, the base 366 of the header member 334 may be in the form of a metal plate having a length L8 of about 13 in., a width W8 of about 6.5 in. and a thickness T8 of about 0.5 in., and the posts 338 of the header members may be formed by tubular metal pipes welded to the plate, each such pipe having a height H8 of about 3.5 in. and an outside diameter OD of about 1.625 in. (see FIGS. 28 and 29). The channels 372 may also be formed from metal plate having an overall height H9 of about 5.5 in., an opening width W9 of about 5.5 in., an opening depth D9 of about 6 in., and a wall thickness of about 0.5 in. The header members 334 can have other configurations without departing from the scope of this invention.

As best shown in FIGS. 27 and 30, a seal comprising a pair of gaskets 380 are positioned between the panel 350 and the side walls 52 of the modular units 24 facing the panel to seal the relatively wide junction 30 (gap) between the two units 24. The gaskets 380 are of a compressible sealing material, such as a sealing foam material. Desirably, the gaskets 380 are adhesively secured to the inside face of the connector panel 350 and have a thickness such that they are compressed between the panel and respective side walls 52 of the modular units 24 when the connecting and sealing device 320 is installed. By way of example, each gasket 380 may be a 1.0 in. to 1.5 in.-thick sheet of closed-cell, water-resistant foam material having a peel-off backing layer for ready application of the foam to the connecting panel. Other gasket configurations are within the scope of this invention.

The “expansion” connecting and sealing device 320 can be used to construct a floodwall, or at least one or more segments of a floodwall, in which modular units 24 are spaced farther apart than when using the first-described connecting and sealing device 34. An advantage of using the expansion connecting and sealing device 320 is that fewer modular units are required to construct the floodwall, thus reducing overall cost. In general, the use of this “expansion” feature is most appropriate at locations where the flood waters are shallow and/or slow moving.

The “expansion” connecting and sealing device 320 described above can also be used for connecting and sealing two second modular units 28 and/or for connecting and sealing first modular unit 24 and a second modular unit 28. The connection process is substantially identical in each instance.

The modular floodwall system 20 is designed for rapid deployment. The modular units 24, 28 are transported (e.g., by low-boy transportation trailers) to the site of a flood where they are unloaded, placed in position, and connected to form a floodwall having a desired configuration. The deployment process is described below.

The larger modular units 24 can be connected in either an end-to-end configuration or an end-to-side configuration. To connect two units 24 end-to-end, a fork lift truck or other lifting device is used to place a first unit 24 on the ground at an appropriate location, and two footers 200 are positioned adjacent the corners posts 60 at one end of the unit. The end of the unit 24 is lifted and then lowered to insert two connecting posts 224 of the footers 200 into the holes 228 at the lower ends of the two corner posts. After the unit is lowered, a second modular unit 24 is placed end-to-end with the first unit such that the other two connecting posts 224 of the footers 200 are received in respective holes 228 in the lower ends of the two corner posts 60 at the adjacent end of the second unit. The lower ends of two vertical connecting members 210 are placed in the slots 270 of the two footers 200 to cover the junction 30 between the first and second modular units 24 at opposite sides of the floodwall, and the headers 204 are placed in position with the upper ends of the vertical connecting members 210 extending up through the slots 272 in the headers and the connecting posts 244 of the headers extending down into the holes 250 at the upper ends of respective corner posts 60 of the two units. With the headers 204, footers 200 and vertical connecting members 210 in place, the side-seal gaskets 214 are compressed between the connecting members 210 and the side walls 52 of the modular units 24 to seal the junction 30 between the units against floodwater.

For additional sealing protection, an end-seal gasket 300 is applied to an end of one of the two units 24 being connected before the units are placed end-to-end. When the units are connected, the end-seal gasket 300 is compressed between adjacent ends of the two units to seal the junction 30.

A similar process is used to connect two modular units 24 in an end-to-side configuration. However, for this configuration, only one connecting and sealing device 34 is used to connect the units and seal the junction 30 at the floodwall side of the units. Optionally, an end-seal gasket 300 may be used for additional sealing protection.

Two smaller (½-size) modular units 28 can be connected end-to-end in a manner similar to that described above for connecting two larger units 24 end-to-end, except that only one connecting and sealing device 34 is used to seal the junction 30 at the floodwall side of the units. Optionally, an end-seal gasket 300 may be used between the units for additional sealing protection. In this application, the end-seal gasket 300 has a triangular shape to match the shape of the end walls 166 of the two units 28.

Advantageously, the same connecting and sealing device 34 can also be used to connect a first modular unit 24 end-to-end to a second modular unit 28 and to seal the junction 30 between them. The process for connecting the two units 24, 28 is identical to the process described above for connecting two first modular units 24 end-to-end, except that only one connecting and sealing device 34 is used (see FIG. 2). Optionally, an end-seal gasket 300 between the two units may be used for additional sealing protection. In this application, the end-seal gasket 300 has a triangular shape to match the shape of the end wall 166 of the smaller triangular unit 28.

The modular units 24, 28 of the floodwall 20 can also be connected at appropriate locations using the “expansion” connecting and sealing devices 320 described above. For example, the “expansion” devices can be used where the flood waters are more shallow and/or slower-moving, thereby reducing the number of modular units needed to construct the floodwall.

The modular units 24, 24′, 28 and the connecting and sealing devices 34, 320 are selectively used to construct a floodwall having a configuration designed to meet the specific needs of each flood control site. For example, the larger and heavier modular units 24, 24′ can be used to control large amounts of fast-moving flood water, and the smaller and lighter units 28 can be used to control shallow, slower moving flood waters where the forces exerted on the floodwall are less. Further, modular units 24, 24′, 28 of different types can be strung together to form a floodwall which is designed to meet the specific characteristics of the site, such as the path followed by the flooding waterway, the depth of the floodwaters, the speed of the flood water, and the layout of the property being protected. For instance, as shown in FIG. 1, a series of larger heavier modular units 24, 24′ are connected to form a first segment 20A of the floodwall along a first section of a flooding waterway subject to relatively larger water-flow forces, and a series of smaller lighter units 28 are connected to form a second segment 20B of the floodwall along a second section of a flooding waterway subject to relatively smaller water-flow forces. Additional modular units of the appropriate type or types can be connected to form additional segments of the floodwall, as needed. The segments are connected to one another using the connecting and sealing devices 34, 320 to form an integrated floodwall system that is custom-tailored according to the expected nature of the flooding and the site-specific requirements of the property being protected.

The modular units 24, 24′, 28 can also used to construct back-up or secondary floodwalls, if needed or desired. For example, if floodwaters are expected to rise to a level that exceeds the height of the modular units 24, 24′, 28 making up a first (primary) floodwall, a second floodwall using additional modular units 24, 28 can be formed a suitable distance spaced from the first floodwall, on the protected side of the first floodwall, to form an additional barrier.

The modular units 24, 24′, 28 are filled with the appropriate amounts of water, using the pump units 108. In general, a unit 24, 24′, 28 is filled soon after it is connected to another unit, although this is not essential. However, a modular unit should be filled before it is exposed to substantial floodwaters so that it has weight sufficient to resist being moved by the floodwaters. The process of connecting and filling the modular units can be completed in a relatively short amount of time, e.g., 10 minutes per unit on average, for a total set-up time of 15.4 hours for a one-mile long floodwall comprising 185 modular units, including 79 40-foot long units 24 and 106 20-foot long units 24, using two pump units 108 pumping at a rate of about 1700 gallons/minute to fill each modular unit to 50% of its capacity.

As illustrated in FIGS. 12-15, barriers 400 of sandbags and/or plastic sheeting or the like may be placed at the base of each modular unit 24, 24′, 28 on the flood water side of the unit and, optionally, on the opposite (protected) side of the unit, to prevent or at least inhibit the seepage and flow of water below the modular units.

After flooding has subsided, the modular-unit floodwall system 20 of this invention can be readily disassembled and removed from the flood site. Water is pumped out of the modular units 24, 24′, 28 using the one or more pump units 108. The units are disconnected by reversing the steps described above. After disconnection, the units are loaded onto suitable carriers and transported away from the flood site for storage. The modular units are cleaned by flushing them with cleaning fluid (e.g., fresh water) which is allowed to drain through the opened drain ports 134. The cleaning will typically takes place at the storage site, but the units can also be cleaned at the flood site before storage. It will be observed, therefore, that the time and expense of clean-up is substantially reduced compared to that required for conventional floodwalls made from sandbags, for example. Further, the modular units 24, 24′, 28 can be used more than once and are easy to store when not in use.

Having described the invention in detail, it will be apparent that modifications and variations are possible without departing from the scope of the invention defined in the appended claims. It will also be apparent that a modular-unit floodwall system of this invention has numerous advantages, including but limited to: engineering superiority; engineering strength; flexibility of configuration; protection superiority; ease and speed of set-up; ease and speed of clean-up; and re-use of the components of the system.

When introducing elements of the present invention or the preferred embodiments(s) thereof, the articles “a”, “an”, “the” and “said” are intended to mean that there are one or more of the elements. The terms “comprising”, “including” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.

In view of the above, it will be seen that the several objects of the invention are achieved and other advantageous results attained.

As various changes could be made in the above constructions and methods without departing from the scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying shall be interpreted as illustrative and not in a limiting sense. 

1. A modular-unit floodwall system comprising modular floodwall units adapted for holding water, each unit having a bottom wall, opposite end walls and side walls, and connecting and sealing devices for connecting the units and sealing junctions between the units to form a barrier against floodwater, each connecting and sealing device comprising a footer configured for connecting two units together generally adjacent the bottom walls of the units, a header configured for connecting the two units together adjacent the top walls of the units, a generally vertical connecting member connecting the footer and the header and extending across a junction between the two units, and a seal on the connecting member for sealing the junction.
 2. A modular-unit floodwall system as set forth in claim 1, wherein said footer comprises a base having connector components configured for releasable connection with mating connector components on said two units.
 3. A modular-unit floodwall system as set forth in claim 2, wherein said connector components comprise a pair of spaced-apart posts extending up from the base, and wherein said mating connector components on said two units comprise holes in adjacent lower corners of the units for receiving said posts.
 4. A modular-unit floodwall system as set forth in claim 3, wherein said base has an opening for removable reception of a lower end of said generally vertical connecting member.
 5. A modular-unit floodwall system as set forth in claim 4, wherein the lower end of the generally vertical connecting member is configured to project down through the base opening and to penetrate the ground.
 6. A modular-unit floodwall system as set forth in claim 1, wherein said header comprises a header base having connector components configured for releasable connection with mating connector components on said two units.
 7. A modular-unit floodwall system as set forth in claim 6, wherein said connector components comprise a pair of spaced-apart header posts extending down from the header base, and wherein said mating connector components on said two units comprise holes in adjacent upper corners of the units for receiving said header posts.
 8. A modular-unit floodwall system as set forth in claim 1, said footer comprising a pair of spaced apart footer members having connector components configured for releasable connection with mating connector components on said two units, said header comprising a pair of spaced apart header members having connector components configured for releasable connection with mating connector components on said two units, and said connecting member comprising a panel having top, bottom and side edges configured for removable reception in respective openings in said footer and header members.
 9. A modular-unit floodwall system as set forth in claim 8, wherein said openings in the footer and header members are defined by channels on respective footer and header members.
 10. A modular-unit floodwall system as set forth in claim 9, wherein said seal comprises a gasket of compressible material on an inner surface of said panel.
 11. A modular-unit floodwall system as set forth in claim 1, wherein a first of said modular floodwall units comprises an elongate rigid structure that is generally rectangular as viewed from an end of the unit, and wherein a second of said modular floodwall units comprises an elongate rigid structure that is generally triangular as viewed from an end of the unit.
 12. A modular-unit floodwall system as set forth in claim 11, wherein said second modular floodwall unit is shaped as a right-triangle as viewed from an end of the unit.
 13. A modular-unit floodwall system as set forth in claim 1, wherein said modular floodwall units comprise a first plurality of units having a first water-holding capacity and a second plurality of units having a second water-holding capacity less than said first water-holding capacity.
 14. A modular-unit floodwall system as set forth in claim 1, wherein at least some of said floodwall units have top walls extending between the side walls, and openings in the top walls for pumping water into or out of a respective floodwall unit.
 15. A modular-unit floodwall system as set forth in claim 1, further comprising a pump-guide system on the top walls for guiding one or more mobile pumps along the top walls.
 16. A floodwall system as set forth in claim 1, wherein each floodwall unit defines an interior space divided by a bulkhead into a water-holding tank compartment and a dry storage compartment accessed by a door in an end wall of the unit.
 17. A floodwall system as set forth in claim 1, wherein said connecting and sealing devices are configured for connecting at least some of the modular units either end-to-end or end-to-side.
 18. A modular floodwall unit comprising a rigid box-like structure having a top wall, a bottom wall, opposite end walls and opposite side walls, said structure having a water-holding capacity of at least 1800 cubic feet, at least one opening in the top wall, and a pump-guide system on the top wall for guiding a mobile pump along the top wall.
 19. A modular floodwall unit as set forth in claim 18, wherein said structure defines an elongate interior space divided by a bulkhead into a water-holding tank compartment and a dry storage compartment accessed by a door in an end wall of the structure.
 20. A modular floodwall unit for controlling flood water, comprising a rigid elongate structure having a bottom wall, opposite end walls, a pair of corner posts extending up from the bottom wall adjacent the end walls, a first generally vertical side wall extending up from the bottom wall and secured to the corner posts, and a second inclined side wall sloping up from the bottom wall to the first side wall, and openings in upper and lower ends of the corner posts for receiving connecting devices for connecting the modular floodwall unit end-to-end to adjacent modular floodwall units, said structure having a generally triangular shape as viewed from an end of the structure.
 21. A method of constructing a floodwall from modular floodwall units comprising a first plurality of first modular units having a first water-holding capacity and a second plurality of second modular units having a second water-holding capacity less than said first water-holding capacity, said method comprising the steps of connecting a plurality of first modular units and a plurality of second modular units together, and sealing junctions between the modular units to form a floodwall.
 22. A method as set forth in claim 21, wherein said connecting step comprises connecting a plurality of first modular units to one another to form a first segment of the floodwall, connecting a plurality of second modular units to one another to form a second segment of the floodwall, and connecting said first and second segments of the floodwall.
 23. A method as set forth in claim 22, wherein some modular units are connected end-to-end and other modular units are connected end-to-side.
 24. A method as set forth in claim 21, wherein each first modular unit comprises a rigid structure having a generally rectangular shape as viewed from an end of the structure, and wherein each second modular unit comprises a rigid structure having a generally triangular shape as viewed from an end of the structure. 